Removing and installing the gearbox
Removal and installation of all types of gearboxes are carried out in the same way.
- Disconnect the ground cable from the battery.
- Open the tap and drain the coolant until the coolant level drops below the upper water hose.
- Remove the air filter along with the air intake hose (injection engine).
- Disconnect the wire from the reverse light switch.
- Disconnect the speedometer shaft. To do this, unscrew the knurled nut.
- Disconnect the gear shift cable in accordance with Figure 169. To do this, remove the spring clip and washer and pull the spring clip out of the mount
Pic. 169. Method of fastening the gear selection cable (1) and shift cable (2).
- Remove the coolant inlet. It is secured with a bolt and nut.
- With an S50 type gearbox installed, pull out the spring clip connecting the clutch cylinder hose and tube and unscrew the gearbox mount. With a C52 type gearbox installed, you can unscrew the clutch slave cylinder from the gearbox and move it carefully, without disconnecting the tubes, to the side. This eliminates the need to bleed the clutch hydraulic system after installing the gearbox.
- Unscrew the lower beam casings (left and right).
- Remove the front and rear transmission mounts. If a protective cover is installed, remove it first. After this, unscrew the bolts on the sides shown in Figure 170 and remove the suspension.
Pic. 170. Unscrew the front and rear gearbox suspensions in the indicated locations.
- Remove the engine mount center beam (Pic. 171). The beam is attached outside and in the middle.
Pic. 171. The middle beam of the engine mount is mounted outside and in the middle
- Disconnect the drive shafts from the gearbox as described in Chapter 11.1. The shafts are screwed to the drive flanges of the differential axles, or inserted into the differential gears.
- Disconnect the wires from the starter and remove the starter.
- Disconnect the ground wire.
- On all boxes except S50, unscrew the plate on the rear side of the engine.
- Raise the gearbox with a jack (place a wooden spacer between the jack and the frame) and remove the left engine mount.
- Remove the bolts connecting the transmission and engine, lower the left side of the engine and slowly lower the transmission on the jack.
Installation of the gearbox is carried out in reverse order, taking into account the following points:
- Place the gearbox on a jack to the engine and engage the splined part of the crankshaft with the hub of the clutch driven disc. Tighten the bolts connecting the gearbox to the engine with a diameter of 12 mm with a tightening torque of 65 Nm, with a diameter of 10 mm on the gearbox S50—40 Nm, all other bolts with a torque of 47 Nm.
- Install the left engine mount. Tighten the bolts to 53 Nm.
- Tighten the starter mounting bolts to 40 Nm.
- If the drive shafts are attached to the gearbox on boots, tighten the bolts to a torque of 37 Nm.
- Install the engine mount center beam with a bolt tightening torque of 40 Nm.
- Install the front and rear engine mounts with a bolt tightening torque of 40 Nm.
- Pour oil into the gearbox. Place 2.6 liters of liquid in the S50 box; Pour 2.6 liters of SAE 75V 90 or 80W-90 oil into the C52 box.